Process of Manufacturing Resilient, Fibrous, Piled Woven Fabric

ABSTRACT

A process of manufacturing a resilient, fibrous, piled woven fabric includes moving a resilient, fibrous woven fabric through a platform type carding machine including at least one first roller having a rough surface, at least one second roller having a surface formed of needles, and at least one third roller having a fine surface. One surface of the woven fabric passes and contacts the first roller so that fibers on one surface of the woven fabric are cut, one surface of the woven fabric passes and contacts the second roller so that the fibers on one surface of the woven fabric are broken to form a layer of uneven pile structure thereon, and one surface of the woven fabric passes and contacts the at least one third roller so that the layer of uneven pile structure is combed out and smoothed to finish a resilient, fibrous, piled woven fabric.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention relates to process of manufacturing resilient, fibrous, piled woven fabric and more particularly to a process of manufacturing a resilient, fibrous, piled woven fabric by moving a resilient, fibrous woven fabric to a platform type carding machine in which one surface of the woven fabric passes and contacts first rollers having a rough surface, second rollers for carding, and third rollers having a fine surface so that a resilient, fibrous, piled woven fabric is obtained at the end of the process.

2. Description of Related Art

Clothing is fiber and textile material worn on the body. Physically, clothing serves many purposes including protection, enhancing safety during hazardous activities, insulating against cold or hot conditions, providing a hygienic barrier, and keeping infectious and toxic materials away from the body.

Piled knitting fabrics are exemplary examples of manufacturing clothing for keeping body warm. A conventional knitting fabric has loops and is sufficiently resilient and thus a conventional carding machine can produce pile on the conventional knitting fabric. A conventional process of manufacturing a resilient, fibrous, piled knitting fabric comprises arranging a plurality of platform type carding machines in series, moving an endless, continuous knitting fabric to the platform type carding machines for combing out and cleaning the fibers of the knitting fabric, moving the continuous knitting fabric to a pile cutting machine for trimming, and drying to obtain a finished continuous, resilient, fibrous, piled knitting fabric. However, the conventional process is disadvantageous due to complicate steps, high manufacturing cost and bulkiness of the plurality of machines.

Conventional woven fabrics lack loops and are not piled, do not have the extent of looseness of knitting fabric, and do not have a sufficient force to withstand stretching in the carding step. Furthermore, the conventional carding machines are not configured to process the resilient, fibrous woven fabrics. For overcoming the problem, there was proposed a conventional piled knitting fabric 50 is shown in FIG. 6 and comprises a layer of resilient, fibrous woven fabric 52 attached to one surface by means of an adhesive 56, and a layer of pile structure 54 formed on the other surface. However, the conventional piled knitting fabric 50 has the following disadvantages: The production of the two-layer (i.e., layers 50 and 52) knitting fabric is a time consuming, complicated manufacturing process. The manufacturing cost is prohibitively high. The adhesive 56 is not reliable. In often times, the layer of resilient, fibrous woven fabric 52 may disengage from the piled knitting fabric 50 after a short period of time of use or several times of washing.

Thus, the need for improvement still exists.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a process of manufacturing a resilient, fibrous, piled woven fabric by using a comprising the step of moving a woven fabric through a platform type carding machine in cooperation with a platform for breaking surface fiber, combing out piles and smoothing the piles so as to give an effect of platform combination and process simplification.

In one aspect of the invention, there is provided a process of manufacturing a resilient, fibrous, piled woven fabric comprising the step of moving a resilient, fibrous woven fabric through a platform type carding machine including at least one first roller having a rough surface formed of abrasive material, at least one second roller, a surface of each of the at least one second roller being formed of needles, and at least one third roller having a fine surface formed of less abrasive material wherein one surface of the resilient, fibrous woven fabric passes and contacts the at least one first roller so that fibers on one surface of the resilient, fibrous woven fabric are cut, one surface of the resilient, fibrous woven fabric passes and contacts the at least one second roller so that the fibers on one surface of the resilient, fibrous woven fabric are broken to form a layer of uneven pile structure thereon, and one surface of the resilient, fibrous woven fabric passes and contacts the at least one third roller so that the layer of uneven pile structure is combed out and smoothed to finish an endless, continuous, resilient, fibrous, piled woven fabric.

The invention has the following advantages and benefits in comparison with the conventional art: The process of cutting the fibers with the carding machine, breaking the fibers with a rough roller, combing out the fibers, and smoothing the fiber with a fine roller is executed by cooperating with the platform type carding machine. Further, three different types of rollers are incorporated into a platform can simplifying process, saving space occupied by many platforms, and saving the manufacturing time. Further, a resilient, fibrous, piled woven fabric having a single layer structure and a single pile surface is produced so that the problem of the fabric being peeled as experienced in the conventional fabric having a two-layer structure is eliminated

The above and other objects, features and advantages of the invention will become apparent from the following detailed description taken with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart of a process of manufacturing resilient, fibrous, piled woven fabric according to the invention;

FIG. 2 is a side elevation schematically depicting an apparatus of manufacturing the resilient, fibrous, piled woven fabric according to the invention;

FIG. 3 is a perspective view of the platform type carding machine;

FIG. 4 is an enlarged view of the platform type carding machine shown in FIG. 2;

FIG. 5 is a longitudinal sectional view of the resilient, fibrous, piled woven fabric; and

FIG. 6 is a longitudinal sectional view of a conventional resilient, fibrous, piled knitting fabric.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a process of manufacturing resilient, fibrous, piled woven 30 fabric in accordance with the invention is illustrated. The process comprises the following steps:

moving a resilient, fibrous woven fabric 10 through a dryer 15 to dry and comb out the resilient, fibrous woven fabric 10;

moving the resilient, fibrous woven fabric 10 through a platform type carding machine 20 in which one surface of the resilient, fibrous woven fabric 10 passes and contacts at least one first roller 22 having a rough surface, at least one second roller 24 for carding, and at least one third roller 26 having a fine surface so that the purposes of cutting fibers, combing out the pile, and smoothing the pile for greatly decreasing the probability of the resilient, fibrous woven fabric 10 having wrinkles when entering the platform type carding machine 20 can be obtained. Further, a plurality of positioning rollers 28 are provided above the first, second and third rollers 22, 24 and 26 in which each positioning roller 28 is disposed between two adjacent first rollers 22, two adjacent second rollers 24, two adjacent third rollers 26, two adjacent first and second rollers 22 and 24, or between two adjacent second and third rollers 24 and 26. The positioning rollers 28 are lowered to press and flatten the resilient, fibrous woven fabric 10; and

finishing an endless, continuous, resilient, fibrous, piled woven fabric 30.

Referring to FIGS. 2 and 3, an apparatus tied to the process of manufacturing a resilient, fibrous, piled woven fabric 30 in accordance with the invention comprises the dryer 15 and the platform type carding machine 20 in which the dryer 15 has six rollers and the resilient, fibrous woven fabric 10 passes the rollers sequentially. Thus, the purposes of cutting fibers and combing out the pile can be obtained. At the entrance and exit of the platform type carding machine 20, there are provided two sets of two opposite fourth rollers (e.g., upper and lower fourth rollers) 29 respectively in which the set of fourth rollers 29 at the entrance of the platform type carding machine 20 are adjacent to the first roller 22 and the set of fourth rollers 29 at the exit of the platform type carding machine 20 are adjacent to the third roller 26.

Referring to FIG. 4, the pair of opposite rotating fourth rollers 29 may press the passing resilient, fibrous woven fabric 10. Next, the resilient, fibrous woven fabric 10 passes and contacts the first rollers 22. The rough surfaces of the first rollers 22, characterized similarly to sandpaper, cuts the fibers on the lower surface of the resilient, fibrous woven fabric 10. Further, the resilient, fibrous woven fabric 10 passes and contacts the second rollers 24. The surfaces of the second rollers 24 formed with needles are configured to break the fibers on the lower surface of the resilient, fibrous woven fabric 10. Thereafter, a layer of uneven pile structure 32 is formed on the lower surface of the resilient, fibrous woven fabric 10. Furthermore, the resilient, fibrous woven fabric 10 passes and contacts the third rollers 26. The surfaces of the third rollers 26 coated with less abrasive material are configured to comb out and smooth the layer of uneven pile structure 32. As a result, the endless, continuous, resilient, fibrous, piled woven fabric 30 is formed.

Referring to FIG. 5, the resilient, fibrous, piled woven fabric 30 comprises the layer of uneven pile structure 32 formed on the resilient, fibrous woven fabric 10.

The invention has the following characteristics and advantages: The resilient, fibrous, piled woven fabric 30 has an excellent resilience. People wearing an article of clothing made by the resilient, fibrous, piled woven fabric 30 may feel warmness. The resilient, fibrous, piled woven fabric 30 has only one surface provided with pile. No additional knitting fabric is required for forming the pile.

While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims. 

What is claimed is:
 1. A process of manufacturing a resilient, fibrous, piled woven fabric comprising the step of: moving a resilient, fibrous woven fabric through a platform type carding machine including at least one first roller having a rough surface formed of abrasive material, at least one second roller, a surface of each of the at least one second roller being formed of needles, and at least one third roller having a fine surface formed of less abrasive material wherein one surface of the resilient, fibrous woven fabric passes and contacts the at least one first roller so that fibers on one surface of the resilient, fibrous woven fabric are cut, one surface of the resilient, fibrous woven fabric passes and contacts the at least one second roller so that the fibers on one surface of the resilient, fibrous woven fabric are broken to form a layer of uneven pile structure thereon, and one surface of the resilient, fibrous woven fabric passes and contacts the at least one third roller so that the layer of uneven pile structure is combed out and smoothed to finish an endless, continuous, resilient, fibrous, piled woven fabric.
 2. The process of manufacturing a resilient, fibrous, piled woven fabric of claim 1, wherein before step of resilient, fibrous woven fabric movement further comprises the step of moving the resilient, fibrous woven fabric through a dryer to dry and comb out the woven fabric.
 3. The process of manufacturing a resilient, fibrous, piled woven fabric of claim 1, further comprising a plurality of positioning rollers disposed above the first, second and third rollers.
 4. The process of manufacturing a resilient, fibrous, piled woven fabric of claim 1, wherein at an entrance of the platform type carding machine, there are provided with two opposite fourth rollers, and at an exit thereof, there are provided with another two opposite fourth rollers.
 5. The process of manufacturing a resilient, fibrous, piled woven fabric of claim 1, wherein the number of the at least one first roller is two, the number of the at least one second roller is two, and the number of the at least one third roller is two. 